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How to effectively prevent compressed air leaks?

2024-06-01View Original

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When purchasing an air compressor, it is common to leave a margin of about 10% based on the actual gas consumption, in order to account for potential leaks or increases in gas usage. Many enterprises' compressed air systems suffer from some degree of leakage, with the leakage rate accounting for 20% to 40% of the air supply volume; in some cases, it even reaches 50% or more. Leaks often occur due to inadequate maintenance during regular use. According to the experience from the compressor encyclopedia, if a leak is detected, the costs associated with inspection or repair can recover the initial investment cost within half a year. Enterprise equipment personnel should carry out leakage assessment and repair as part of their daily tasks. In daily operations, it is necessary to check for leakage points in order to detect and address them promptly; meanwhile, conducting regular inspections of the gas pipelines for leaks can help reduce energy waste effectively. Choose high-quality pipes and fittings. Leaks in compressed air generally occur mainly in the gas pipelines and pipe fittings. Therefore, when purchasing pipes and other accessories, one should choose high-quality pipe fittings, connection devices, hoses, and pipes from well-known brands. These are the prerequisites to ensure no leaks in compressed air. Of course, the quality of installation also has a significant impact on leaks; therefore, it is important to hire engineers with excellent technical skills for the installation. Reduce pressure drop and stabilize supply pressure. With the same pipe size, lowering the system pressure can effectively reduce leakage rates; it also has a positive effect on energy savings for air compressor equipment (a 1 bar reduction in pressure can result in approximately 7% less energy consumption). A stable compressed air pressure can effectively ensure the proper operation of equipment that relies on air supply; it is only under the pressure-stabilizing action of a pressure regulator that it becomes possible to consider the system operating at reduced pressure. When the leakage pressure is insufficient, it is necessary to increase the gas generation pressure to ensure the proper operation of the gas-using equipment; therefore, improving the sealing condition of the pipeline network is an important condition for operating at reduced pressure. Equipment that does not require gas supply should have its gas supply cut off. If there are gas pipes connected to devices that do not need gas, these represent leakage points; therefore, it is necessary to disconnect the gas supply to such devices in order to reduce unnecessary energy consumption. For gas-using equipment that operates periodically or with fluctuations, the gas supply should also be cut off when it is not in use. Properly conduct inspections of compressed air; the amount of air leaking through a 1mm aperture is equivalent to the compressed air produced by a 0.4kW compressor. Fixing leaks promptly can **reduce waste**. Common leaks occur mainly in hose ruptures, condensate drain valves, pressure control valves, as well as pipe joints and quick-connect fittings. ✦ Summary ✦ It is actually difficult to achieve zero leaks in real compressed air systems; the goal is mainly to keep leaks within a reasonable range. Leaks not only result in additional energy consumption but also cause instability in system pressure, thereby affecting gas-using equipment. Increasing the gas pressure can also result in additional energy consumption; therefore, it is very necessary to check for leaks.

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